Applying resistance deposits to radio volume control disks



Oct. 21, 1941.

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APPLYING RESISTANCE DEPOSITS TO RADIO VOLUME CONTROL DISKS Les ATTOR 'VEYS.

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WITNESSES: %W2d Oct. 21, 1941. c. c. SCHAEFER ETAL APPLYING RESISTANCE DEPOSITS TO RADIO VOLUME CONTROL DISKS Filed June 10, 1939 13 Sheets-Sheet l1 INVENTORS c fer olle spn 8: man i. zed

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Oct. 1941- c. .C. SCH'AEF'ER ETAL ,2

APPLYING RESISTANCE DEPOSITS TO RADIO VOLUME CONTROLDISKS Filed June 10, 19:9

13 Sheets-Sheet '13 ATTORNEYS.

Patented Oct. 21, 1941 APPLYING RESISTANCE DEPOSITS TO RADIO VOLUME CONTROL DISKS Charles C. Schaefer and Satan A. Tollefson, Oaklyn, and Herman F. Nied, Camden, N. J.

Application June 10, 1939, Serial No. 278,574

28 Claims. (Cl. 9155) This invention relates to the application of resistance deposits to Bakelite or analogous material disks and, more particularly, to the type of disk employed as a substitute for wire windings in rheostats of radio volume control units, and differentially coated with silver and carbon to vary the ohms resistance capacity. Heretofore disks of the kind referred to have been manually coated by the aid of a suitable spray gun with consequent lack of uniformity in the degree of intensity and resultant heavy wastage both of disk material as well as the resistance deposits.

The primary aim of this invention is to positively eliminate the noted Wastages in addition to producing disks coated, as required, with resistance deposit of accurately determinable intensity and uniform area.

Another object is to provide an automatic mechanism for applying resistance deposits of consistent fluency irrespective of the required density or thickness so that the ohms resistance can be accurately gauged, and said deposit or deposits applied without intervening interference when changing the per cent of total resistance in radio volume control units.

A further object is the provision of a machine adapted to automatically apply differential areas of resistance deposit to rheostat disks in consecutive order and definite relation with preassurance that any multiplicity of such disks can be successively produced without potential resistance differentiation.

A still further object of this invention is to provide a machine as indicated in the preceding paragraph equipped with pressure influenced deposit-effecting nozzles adapted to eject an annular spray of the resistance deposit without the slightest deviation from concentrieity and incidental to emission thereof to compact said spray by opposing air jets to predetermined elongate configuration.

Another object of this invention is to provide a machine for applying resistance deposits intermittently to disks of the typified character as said disks are transported by a continuously moving conveyor, and to concurrently feed-in the successive disks without stoppage of the said conveyor.

A further object is to provide a machine of the typified character including means functional to simultaneously adhere the resistance deposit to the disk as applied, to the avoidance of any spread, and to gradually dry the same until the consecutive disks are transferred from the machine for subsequent baking.

Still another object is to provide a machine as above indicated including a continuous conveyor and means operative to effectively clean the conveyor disk carriers and deposit controlling masks after removal of the treated disks before reaching the entrant end of the machine.

Other objects of a tributory character in addition to ancillary advantages achieved by this invention will be apparent from, or specifically noted in, the following description; and it may be said to essentially comprise the elements and combinations of the same, features of construction, and arrangements of parts that are typically shown in the preferred embodiment illustrated by the accompanying sheets of drawings, and the scope of application whereof is more particularly defined in the concluding claims.

In the drawings:

Fig. 1 is a side elevation of a machine for applying resistance deposits to rheostat disks adapted for use in radio volume control units and embodying the constructive features of this invention.

Fig. 2 is an end elevation within the limits of the arrows 2-4 at the left-hand or discharge end of the machine shown in the preceding illustration, but drawn to a larger scale for clarity.

Fig. 3 is a top plan view within the confines of the plane indicating arrows 33 at the righthand or feed-in end of Fig. 1, also drawn to a larger scale for clearer illustration of important details.

Fig. 4 is a plan section of the disk magazine and mechanism for feeding the successive disks to the conveyor means, said section being taken approximately on the staggered plane 4-4 of Fig. 5.

Fig. 5 is a part section and part elevation on the plane 5-5 in Figs. 1 and 3.

Fig. 6 is a fragmentary sectional elevation, Within the limits of the arrows 6--6 in Fig. 3, or through the feed portion of the disk magazine, drawn to a larger scale than in Fig. 5, to better illustrate how successive disks are initially re- I moved from the magazine for transfer into registration, with the conveyor carrier elements.

Fig. 7 is a fragmentary elevation and part sectional view on the staggered-plane 1-1 of Fig. 6, but drawn to a smaller scale.

Figs. 8 and 9 are fragmentary views similar to Fig. '7, but showing different positions of the disk ejector member in moving the consecutive disks from the magazine into position for application to the conveyor carrier elements.

Fig. (sheet 6) is a fragmentary section, on the plane Ill-I0 of Fig. 6, hereinafter fully explained.

Fig. 11 (sheet 8) is a fragmentary sectional view of the lower central portion of Fig. 6, on a larger scale, showing a disk in position ready for projection against a conveyor chain carrier element.

Fig. 12 (sheet 7) is a plan section, taken approximately as indicated by the arrows I2-I 2 in Fig. 6, and showing suitable pneumatic devices for blowing the successive disks from the transfer means onto an opposing carrier element with adisk in position on said carrier element.

Fig. 13 (sheet 8) is a detail perspective view of a retainer means effective for preventing the disks from dropping away from the feed mechanism transfer means.

Fig. 14 is a fragmentary sectional view through the magazine disk delivering end.

Fig. 15 is a similar view to the preceding as seen from the reverse side thereof and with certain movable parts in a diiferent position.

Fig. 16 (sheet 6) is a fragmentary elevation as viewed from the left-hand and looking towards the right of Fig. 17.

Fig. 17 (sheet 4) is a vertical section on the arrowed planes I'I-I I in Figs. 1, 3 and 16.

Fig. 18 (sheet 6) is a section on the plane lit-48 of Fig. 16.

Fig. 19 (sheet 9) is a plan view of one of the spraying units, said view being taken approximately on the planes designated I9-I 9 in Figs. 1 and 20.

Fig. 20 (sheet 10) is a part elevation and part sectional view on the planes 20'-2il in Figs. 1 and 19.

Fig. 21 is a fragmentary elevation taken within the limits of the plane indicating arrows 2 I-2I of Figs. 19 and 22.

Fig. 22 is a vertical section on the plane 22-22 in Fig. 21.

Fig. 23 (sheet 11) is a sectional elevation through the drying means, said section being taken approximately as indicated by the arrows 2323 in Fig. 20.

Fig. 24 is a plan section through the conveyor cleaning means proximate the disk discharge end of the machine, said section being taken approximately on the plane 24-24 of Fig. 25.

Fig. 25 is a longitudinal section on a vertical plane through the center of the preceding figure.

Fig. 26 is a lateral section on the plane 26-26 of Fig. 25.

Fig. 27 is a cross-section taken as indicated by the arrows 2'I2'I in Fig. 23.

Fig. 28 (sheet 12) is a fragmentary levation of the mechanism operative to remove the disks from the conveyor carrier elements at the discharge end of the machine, said elevation being taken substantially as indicated by the staggered plane 23-28 in Fig. 2.

Fig. 29 is a substantially similar view to the preceding with the remover means in full active position.

Fig. 30 (sheet 13) is a fragmentary plan View of a pressure control hereinafter fully described, said view being taken on the plane 30'30 in Fig. 20;

Fig. 30a is a detail hereinafter specifically explained.

Fig. 31 is a vertical section on the plane 3I-3 I- in Figs. 1, 32 and 33.

Fig. 32 is a fragmentary planview of a horseshoe magnet for removing a trip device, from the selected carrier element, and also serving to actu ate the pressure control means of Fig. 30.

Fig. 33 is an elevation as viewed from below the preceding figure.

Fig. 34 is a fragmentary view in part corresponding with Fig. 33, but showing the trip device released from the conveyor carrier element and held by the horse-shoe magnet.

Fig. 35 is a perspective view of the trip device.

Fig. 36 (sheet 1) is a face vie-w of one of the rheostat disks before application thereto of any resistance deposits.

Figs. 37-41, inclusive, are fragmentary mask views depicting successive operative stages in producing a disk with sectional resistance deposits of varying area and density in accordance with this invention.

Figs. 4246 are paralleling views illustrative of the consecutive deposit applications effected on the disks incident to the operative stages shown in Figs. 37-41; and,

Figs. 47 and 18 (sheet 10) are nozzle details hereinafter fully described.

In the illustrated embodiment of this invention as preferably adapted to the application of resistance deposits of predetermined areas and density to rheostat disks for radio volume control units, the machine comprises parallel framework supports l, of appropriate formation, which are rigidly connected by cross ties 2 and longitudinal braces 3. Suitably sustained by the supports I, as later on further amplified, is a continuously operable conveyor 4; the magazine and feed mechanism comprehensively designated 5; a battery of mask and. deposit applicator means 6; a drying system I; and a disk releasing and discharging mechanism with associated conveyor cleaning means generally marked 8: all of said parts being operatively coordinated for automatic actuation in timed sequence.

Conveniently mountedbetween the supports I is an electric motor 9 and speed-transmission IIl, operatively coupled to the main drive shaft I I, journaled in suitabl bearings I2 at intervals of the framework supports I, said shaft having at its end remote from the motor 9 a bevel gear I3 in mesh with a compl'emental gear i4, fixed on a countershaft I5 rotative in pedestal bearings I6. Fast on the countershaft I5 is a sprocket I'I about which passes a chain drive I8 coactiv with a tooth-drive I 9 rigid on a transverse shaft 20, journaled' in bearings 2I mounted on the framework supports I, at the discharge end of the machine. This shaft 26 has secured thereon a second sprocket drive 22 about which is trained the endless conveyor-chain 23, of special type, and which is similarly coactive witha sprocket 24 keyed to a freely rotative transverse shaft 25, jou'rnaled in bearings 26, at the feed end of the machine, or right hand of Figs. 1 and 3. In its active flight the conveyor-chain 23 traverses or rides on a track 21, provided for the purpose along the top edges of one of the supports I and, during the return flight it is sustained, at intervals, by angle brackets 28', Figs. 24 and 25, each having an associated aligning sprocket 29, onl one such means being indicated insaid figures to avoid confusive illustration. The conveyor-chain 23, it is tobe observed, is of special construction and comprises conventional spaced links 30 with alternating rectangular plate or somewhat T-section components 3| along one side thereof, as best appreciated from Figs; 6, ll, 17, 28 and 29, said components 3| being of greater depth than the width of th links 30 as best shown in Figs. 6,

11, 21 and 22. To each component 3| is afliXed, as by a set-screw 32, a rectangular carrier 33 having an undulate recess 34 in the upper part, and outset opposedly-inclined lugs 35, preferably constituted by the flanges of channel-section elements 36, best seen in Figs. 11 and 12, clamped thereto by set-screws 31, with said flanges engaged through complemental slots in the carrier 33, so as to ensure against relative movement. These flanges or lugs 35 serve to engage through apertures 38 and grip the tapering central part 39 of the rheostat discs 48 tosupport the latter during application thereto of the resistance deposits; and each said carrier 33 is fitted with spaced studs 4|, near the angular corners and hereinafter referred to as mask progressing pins.

To prevent the active flight of the conveyor 4 from lifting as Well as to positively ensure its aligned progression along the track 21, in respect to successive mechanisms involved in the machine, as well as actuated by the conveyorchain 23, said track is fitted at regular intervals of its length with appropriate spacers 42, and a member 43 paralleling such track. This member 43, in conjunction with the track 21 jointly afford smooth guidance for the conveyor links 38 with the T-section components riding along the edge of member 43, as clearly understandable from Figs. 5, 6 and 11, more particularly.

Mounted on one of the framework-supports I, proximate the feed end of the machine, is a rigid fulcrum bracket 44 having pivoted thereto at 45 an actuator-lever 46 to the outer end of which is connected one extremity of a recoil spring 41 having its other end coupled to an anchor member 48, secured at 49 to the end of the support aforesaid Fixed to the actuatorlever 46, with capacity for adjustment as by appropriate clamp means 58 is a pawling element 55 having an antifriction roller 52 at its free end, in turn coactive with a tooth-cam 53 fast on the transverse or driven shaft 25, whereby the lever 46 is rocked on its pivot 45 in opposition to the spring 41, for a purpose later explained. Spanning the framework supports l and attached thereto by spaced brackets 54 and a foot structure 55, Figs. 3, 4, and 6, is the magazine and feed mechanism 5. This mechanism comprises an inclined chute 56 including a bottom bar 51, Fig. 7, side bars 58 and a top bar 59 having an inwardly-directed rib 68 for coaction with the -notch 6| of the rheostat disks 48. The bars 51, 58 and 59 are secured in relative assembly, to afford smooth guidance for a column of rheostat disks 48, by connecting collars 62 with screws 63, in an obvious manner, to ensure accurate parallelism and alignment; while the lower end collar 62 preferably forms part of the foot structure 55, as best understood from Figs. 5 and 6. The foot structure 55 embodies a base 64 with spaced uprights 65 and a relativelyadjustable spanning wall 66, Figs. 4-6, said wall being disposed at right angles to the longitudinal inclination of the chute 56 and having spaced grooves 6! therein for wear bars 68 which are influenced towards the discharge end of said chute by socketed pins 69 under the action of pushers l8 afforded guidance by adjustable screws H, and having springs 12 in compression intermediate the head portions of said screws and the outer face of the pushers 19. It is to be here noted that the socketed pins 69, carried by the wear bars 68, are of such a length to normally project beyond the outer surface of the connecting wall 61 so as to hold the pushers 18 inclined relative to said surface, as clearly shown in Figs. 5 and 6. In addition to the grooves--61 in the foot piece spanning wall 66, the latter has flanking other grooves 13 affording guidance for slide bars 14 connected together at the upper ends by a tie-piece l5, and to which the inner end of the actuator lever 46 is pivotally connected by a shouldered stud 16. Also bridging and rigidly secured to the slide bars 14 is an ejector-plate H of appropriate thickness to remove the successive rheostat disks 48 from the chute 56, as hereinafter set forth; while it is to be particularly observed the ejector-plate I1 is provided with an arcual cut-out I8 and central tongue 19 adapted to jointly coact with the rheostat disk circumferential edge and V-notch 6| respectively, Fig. 8, to effectively prevent displacement or turning movement of the disks 4 during removal from the chute 56; and 88 is a face plate secured to the spaced uprights 65 for retaining the wear bars 68 and slide bars 14 in their respective grooves 6! and 13, said face plate having a cut-out 8|, Figs. 5-7, accommodating reciprocative clearance for the slide bars 14 and tie-piece 15.

' Arranged below the ejector plate 11 and as sociated parts is a disk receiver and temporary holder conveniently in the form of a bar 82 having a longitudinal rib 83 and an inclined interruption or recess 84 in confronting juxtaposition to an air nozzle 85, as well as in special relation to the successive conveyor chain disc carriers 33, as later on again referred to. As will be best understood from Figs. 11-13, inclusive, the interruption 84 defines sectoral edges 86, on which the lower circumferential edge of each consecutive disk 48 released by the ejector plate 11 temporarily rests and is so held by a suitably contoured or undulate spring 81. In addition the bar 82 is also provided with paralleling flexible wires 88 functional to hold the disks 48 against the carrier 33 until effectively held thereagainst by the inclined lugs 35 hereinbefore referred to. In order that the inclined chute 56 may be kept continuously replenished with disks 48, said chute is preferably made in two sections which are connected together by screws 89, with wing nuts 98 respectively secured-in and coactive-with intermediate collars 62, 62", Figs. 3-5, with the one, section being removable by releasing said nuts 98 and lifting from support by the spaced brackets 54, for refilling with disks 48 when emptied, and replacement in an obvious manner. Slidably fitting the chute 56 is a feed block or follower 9| having a radially projecting hook 92, at one side of the chute 56, to which is attached one end of a flexible cord or the like 93, in turn trained around a freely rotative sheave 94 in a bearing 95 carried by the foot structure 55, and a second sheave 96 in a bearing 91 carried by the collar 62 and having a weight 98 at its free end. The follower 9| serves to maintain the column of disks 48 compacted towards the lower end of the chute 56 in contact with the wear bars 68.

In order that the disks 48 may be constantly held under forward influence towards the wear bars 68 when the upper chute section is removed, as aforesaid, for refilling, thereis provided a second pull-influenced means at the opposite side of thechute 56 and comprising a block 99 of suitable cross-section to movably coact with one of the chute side bars 58 and the top bar 59 as clearly shown in Fig. 7. This block 99 normally occupies the position shown in Fig. 5, or in abutment with the foot structure 55, and it is provided with a lateral hook or pin I to which one end of a flexible cord or the like IN is attached, while said cord is trained around a sheave I02 carried by a bearing I03 on the foot structure 55 and a second sheave I04 in a bearing I05 on the collar 62', with a weight I06 at its free end. In addition the block 99 is provided with a push-in slide I01 under control of a spring-influenced snap device I08, best shown in Fig. 15. Now it will be readily understood that when the supply of disks 48 passes below the collar 62 the operator slides the block 99 upwards, as viewed in Figs. 5 and 15, for example, and pushes-in the slide I01 between the uppermost disk 40 and the bottom face of the follower 9| in opposition to the snap device I98. From Fig. it will be seen the inner end of the push-in slide I01 is chamfered down at I09 to aid its free insertion, as well as having a recess I I0 for coaction with the snap device I08 to hold said slide in the active position for feeding the disks 40 forward under influence of the weight I 05. Incident to the operation just described, the operator releases the cord 93 from the follower hook 92, whereupon the chute upper section, and follower 9|, can be removed by disconnecting the wing nuts 90 from the screws 89 and the said section refilled with disks 40 and the follower 9| replaced and attached to the cord 93 after the upper section is reconnected by the wing nuts 90 and screws 89. Obviously, as soon as the disk replenishment is effected, as just explained the slide I01 is retracted when the weight 18 automatically retracts the block 99 to its normal position in abutment with the foot structure 55, and it will be appreciated that by the means described feeding forward of the disks 40 continues uninterruptedly as long as the machine is in operation.

In order to transfer each successively released disk 40 from the inclined recess 84, let it be first remarked the latter is provided with a cut-out IIIinto which the laterally collapsed end I12 of the nozzle 85 projects, Figs. 11 and 12, and that such transfer is effected by intermittent blasts of pressure air emitted by said nozzle. The nozzle 85 is under control of a magnetic valve I I3, in turn actuated by a suitable switch II4, intermittently operated by a spring-influenced angle member II5 fulcrumed by a sleeve I I6, to a pillar II1, secured in a table plate 43' attached to the member 43 by clamp-screws 43", see Figs. 6 and 12 to best advantage. Pressure air is supplied to the valve I I3 through a conventional regulator H8 by a conduit II9 from any convenient source of supply, not shown; while the magnetic switch H4 is actuated to open and close the valve II3 by a trip portion I of the member II5 engaging the head of the channelsection set screws 31, hereinbefore referred to, as the conveyor chain 23. progresses.

At this juncture, note is to be had that, in order to keep the conveyor chain from displacement incident to machine vibration'or other causes, use is made of a floating plate I2I afforded vertical guidance by the sleeve H6, and spaced pins I22 having their upper ends screw threaded for engagement by wing nuts I23 with interposed springs I24, and another guide pin or pins I25 functional to prevent planar inclination of floating plate I2I, said plate having an undercuit groove I29 for coaction with the top edge of the special chain links or T-shaped components 3|. In addition to the means just described and in order to prevent deflection of the carrier members 33, under influence of the pressure air when transferring released disks 40 to said members, a buffer device is provided, said device comprising a bar I21 which is rigidly fixed to the foot structure abutting collar 62 with projection therebelow. Supported by the bar I21 is a buffer member I28 having spaced studs I29 with encircling coil springs I30, housed in holes I3I through said bar, with the opposed ends of the springs I30 engaging a flat adjuster member I32 held in place on the bar I21 by a screw I33. The member I32 is variably flexed to hold the buffer member I28 in such a position that the conveyor carrier members 33 are maintained vertical during successive impacts of the air blasts emitted by the nozzle 85.

In order that the successive disks 40 applied to the consecutive carriers 33 may be firmly retained in position for deposit application and to prevent any rotary movement thereof relative to the inclined lugs 35, use is made of a wedging device seen to best advantage in Figs. 16 and 17, and comprehensively designated I34. This device I34 comprises a vertical bracket I35, secured on the member 43 in proximity to the chute 56, said bracket having guide races I36 in which a slide I31 is movable, while the slide I31 has a freely rotative roller I38 in its lower part, adapted to ride along the top edge of the carrier members 33. This slide I31 is downwardly influenced by a spring I39 anchored at one end to an apertured strap I40 secured across the races I35; and at the other end coupled at I4I to a block I42, vertically adjustable by a screw I43, threadedly engaged in the upper end of the slide I31, and said block I42 is prevented from rotary movement by a guide pin I44 in a clearly apparent manner, while it will be observed the block I42 also serves as a downward movement limiting stop for said slide I31. Now it will be readily seen that as each consecutive carrier 33 upper edge engages the roller I38 and progresses thereunder, said roller will follow the contour of the undulate recess 34 in the top edge of the carrier 33 and engaging the upper circumferential edges of the disk 40, flanking the V-notch BI therein, will impart a diarnetric thrust thereto and force the tapering central part 39 into gripping engagement between the inclined lugs 35, as clearly understandable by comparison of the right and left-hand positional showings in Fig. 16 of said disks. In combination with the wedging device I34 there is provided a laterally effective pusher or holder I45 for coaction with the wires 88 carried by the bar 82, said holder I 45 preferably being in the form of an angle-section slide with suitable projections I43 for coaction with the wires 88, and it is guided in appropriate stationary groove means I41. The holder I45 has an anchorage I48 for one end of a retractile spring I49, the other end whereof is attached to a second anchorage I50 projecting from one of the groove means I41, thus it will be seen the holder I45 is constantly influenced towards the wedging device I34 whereby the conveyor chain special components 3I and attached carriers 33 are held vertical during operation of the disk wedging device I34.

Turning now to the mask and resistance deposit applicator means hereinbefore generally designated 5, inasmuch as the same comprises a series of operatively coordinated corresponding units I5I, Fig. l, the following description will be confined to one unit as more fully shown in Figs. 19-21, in order to dispense with unnecessary repetitive matter, while the relative functions will be later on pointed out. Referring to Fig. 1, it will be observed the units II are operated from the main drive shaft II through the medium of a groove-pulley I52 and V-belt I53 to a similar pulley I54 on a countershaft I55 journaled in bearings I56 along one of the framework longitudinals 3. Fast on the countershaft I55 are pulleys I51 with endless drives I58 respectively coordinated to short shafts I59 journaled in boxes I60, sustained by the machine framework supports I, said shafts having pairs of brushes I6I, I62 fast thereon, for coaction with the inner and outer surfaces of an endless mask I63. The mask I63 is provided with paralleling apertures I64 for engagement with the conveyor chain mask progressing pins 4| and whereby said mask I63 is simultaneously advanced with the conveyor chain 23. The mask N53 is trained about a freely-rotative spool I65 on a stationary vertical shaft I66, carried by a bearing-member I61 from the adjacent support I, as well as stationary spools I68, with arcual guards I69, adapted to guide said mask in close proximity to the conveyor chain 23, and an opening I from a vertical exhaust conduit I1I connecting into a manifold I12 having a discharge outlet I13 to atmosphere, or where desired. Opposing the opening I10 is a funnel-structure I14 in front of which an appropriate spray gun I is mounted, said gun being in communication by a pipe I16 with a receptacle I11 containing solvent resistance deposit, such as carbon or silver, for application to the rheostat disks 40, as later explained. Each receptacle I11 is provided with an agitator I18 driven by a flexible shaft I19, from an associated electric motor I80. Pressure air is supplied from any convenient source by way of a conduit IBI, having a manual shut-off valve I82, into a conventional pressure gauge I83, supported by a bracket I83 from the main frame, and conduit I84 to a magnetic valve I05, and from thence to the spray gun I15. The magnetic valve I85 is actuated by means, preferably in the form of a trip device I86, Fig. 35, removably engaged on the conveyor chain 23 in advance of the mask and deposit applicator means 6. This trip device I66 preferably comprises an inverted U-section or grooved block I 81 embodying a head portion I88 and spaced legs I89, I90, the former of which is longer than the latter. To the leg I90 is secured a spring finger I9I of appropriate contour and dimensions to engage between the conveyor inclined lugs 35 when the device I06 is seated in the undulate recess 34, of the carrier 33, as clearly understandable from Fig. a. The device I86 is placed on the conveyor chain 23 before the machine is started-up or previous to any disks 40 being fed and applied thereto, and it serves by engagement of a rounded corner I92 to shift a spring-influenced pusher-rod I93 for successive actuation of an appropriate switch I94 controlling the magnetic valve I of each unit I5I, whereby pressure air and the desired resistance deposit are continuously sprayed against the mask I63 until the supply in the receptacle I11 is exhausted or the machine is stopped. It is to be observed the lower end of the exhaust conduit IN is closed in at E95 to form a collection pocket for surplus resistance deposit settling therein, or not carried away to the discharge outlet I19; also that the boxes I60 are supplied with appropriate cleaning solution for removal of the resistance material, silver or carbon after the mask I63 passes actively in front of the opening I10, and that rotary electric blower 2 I 1.

the brushes I6I rotate therein; whereas the revolving brushes I62 function to dry-clean said mask before progression over the opening I10. Flanking each side of the opening I10 is a rigidly mounted bracket I96 of Z-section, the upper flange I91 whereof affords guidance for stationary and movable pins I98, I99, respectively, to the latter of which are fixed a guide bar 200 with interposed springs 20I, said bar having a longi-- tudinal groove 202 for coaction with the conveyor chain carriers 33 in maintaining the latter vertical during impact of spray from the gun I15. Furthermore, the bar 200 serves to maintain the mask I63 in true parallelism with the conveyor carriers 33 and thereby positively-ensures engagement of the progressing pins 4| with the mask apertures I64, at all times, during operation of the machine.

Referring to the spray gun I15, and in order to ensure an accurate concentric tubular flow from the nozzle 203, Figs. 19, 20 and 4'1, the conventional needle 204 is provided with a sleeve 205 of a force-fit diameter for engagement in the resistance medium conduit 206, and said sleeve is formed with longitudinal flutings or grooves 291-, for normal flow passage to the tip298. Thus it will be readily understood that by use of the sleeve 205 the needle 204 is firmly sustained axially relative to thetip 208, with the result a predetermined even tubular discharge can be accurately determined by longitudinal adjustment of said needle in accordance with prevailing practice, and Without any remote possibility of the dis- 7 charge becoming eccentric by axial misalignment of the needle tapering end 209 relative to the axis of the tip 208, while it is to be particularly noted said tapering end always projects outwardly beyond the tip orifice as clearly shown in Fig. 47. Furthermore, the air outlet ducts 2 I0 in the nozzle horns 2 I I are diametrically opposed and inwardly angled, as clearly shown in Fig. 47, so as to flatten the tubular discharge of the fluent resistance deposit discharged by the tip- 208, in a vertical direction, for correspondingly directed action against the inner face of the mask I63; or,in other words, at right angles to the path of progression of said mask.

Turning to Fig. l, as well as Figs. 20, 23 and 27 more particularly, which illustrate the drying system 1, it will be seen the same comprises a longitudinal chamber 2I2 having a funnelshaped inlet 2I3, with a tubular section 2I4 in which are located suitable heaters 2I5; said section connecting with an air conduit 2I6 from a In addition the chamher 2 I 2 is provided with a dome portion 2 I 8 above the inlet 2I3, and a series of flue outlets 2I9 communicating into the exhaust conduits I1I, as well as cowl branches 220 having their outlets 22I in close proximity to the conveyor chain carriers 33, intermediate the flue outlets 2I9. Similarly the dome portion 2I8 has an elongated outlet 222 in registration with and lengthwise along the conveyor chain carriers 33 so as to thoroughly dry the resistance deposits on the rheostat disks 40.

Referring back to the trip device I86, andFigs. 31-34 more specifically, provision is made for removing said device in advance of the disk releasing and discharging means 8. In a preferred form, this provision includes a suitable bracket 223 rigidly mounted on the chain track 21, said bracket embodying a lateral inclined flange 224 with which the longer leg I81 of the device I86 engages and coacts to elevate the device I86 vertically, until released from engagement with the conveyor chain carrier 33 for a purpose hereinafter explained. The bracket 223 also embodies an inverted U-section guide portion 225 with which the trip device I86 initially engages as it approaches the inclined track 224 and is pre vented from being knocked ofi the conveyor chain 23 when the leg I81 impacts the lower edge 226 of said track to release the finger I9! from engagement between the carrier inclined gripping lugs 35. In addition the bracket 223 is provided with a top flange 221 to which is firmly secured a permanent horse-shoe magnet 228 which, as the trip device I86 advances into its magnetic field, functions to attract and hold said device clear of further coaction with the conveyor chain 23. The device I86 may thereupon be removed and conveniently placed for re-use as hereinbefore set forth.

Referring now to the disk release and discharging means and conveyor carrier, as well as the chain cleaning mechanism hereinbefore generally designated 8 in Fig. 1, reference will now be made more particularly first to Figs. 2, 28 and 29.

From the last mentioned figures, it will be oba served the main drive shaft I I carries a grooved pulley 229 which is operatively coordinated, by a crossed drive 230, with a corresponding pulley 23! on a short shaft 232, journaled in a suitable bearing 233 rigidly fixed to one of the machine framework supports I. This shaft 232 carries a grooved drum 234, about which passes an endless conveyor 235 adapted to transport the released and treated rheostat disks 4!! into a convenient baking oven, and not shown as it forms no part of this invention. An inclined chute 236 located at the discharge end of the conveyor 4 and supported by bracket means 231 serves to receive and guide the released disks 40 for proper deposit on the conveyor 235 with the coated side up. In order to free the disks 4!] from the conveyor carriers 33, the transverse shaft has fixed thereon a cam gear 238, with which coacts a small roller 239, revolubly supported by a lateral projection 249 from a fulcrum lever 24!, pivoted at 242 to an angle bracket 243, in turn rigidly sustained by the shaft bearing 2|. Pivoted at 244 to the free end of the fulcrum lever 24! is a link 245, in turn having pivot connection at 246 to one end of a kicker 241 fulcrumed by an appropriate bracket 248 to the support I. The bracket 248 has an anchorage projection 249 to which one end of a recoil spring 250 is connected, and said spring has the other end engaged at 25! to the fulcrum lever 24! so as to hold the roller 239 in constant engagement with the cam gear 238, in an obvious manner. From Figs. 2, 28 and 29, it will be noted that as the roller 239 passes over the crest of the cam gear teeth that the levers 24! and 241 will be relatively moved in different angular relationship, also that a laterally projecting pin 252 on the latter coacts with the successive disks 4!! on the conveyor carriers 33, as the latter travel the lower quarter-round path of progression of the conveyor 4 at the commencement of its return flight.

Suitably carried by one of the framework supports I' is a container 253 of appropriate cleaning fluid 254 through which the return flight of the conveyor chain 23 and disk carriers 33 are progressed in order to remove therefrom any adhering resistance deposit, after the disks have been removed as just previously explained. The container'253 is substantially closed-in and is provided with a trough-like extension 255 fitted with an upwardly active stationary brush 256 for brushing the carrier edges as they emerge from said trough extension. Freely rotative in spaced bearings 251 of the container walls 258 are pairs of confronting rotary brushes 259, between which the conveyor return flight and depending carriers 36 are advanced. The shafts 268 of the brushes 259 are respectively provided with grooved pulleys 26! and are operatively coordinated by a crossed belt 262; while one of the shafts 269 has fixed thereon a driver 263 around which passes an endless belt 264, in turn coacting with a larger diameter pulley 265 on the countershaft I5, hereinbefore referred to. In addition, one of the chain aligning angle brackets 28, and freely rotative sprockets 29, is located proximate the brush 256 so as to ensure proper cleaning coaction of the latter with the carrier edges. Spaced stationary brushes 266, Fig. 24, may also be provided in the trough 255 to aid in removing cleaning solution or fluid 254 from the carriers 33 after leaving the rotary brushes 259. In spaced relation to the outlet end of the .trough 255 is preferably located a box like enclosure 261 through which the return flight of the conveyor chain 23 passes, said enclosure having a conduit connection 268 with a centrifugal electric blower 269 whereby pressure air acts on the returning carriers 33 to blow out, or away, any remaining particles of the resistance medium well before said carriers return back into position for application of fresh disks 49.

In Fig. 1 a main starting switch is indicated at 219 for setting the machine conveyor 4 in operation; and 21! indicates the switch controlling the means supplying pressure air to the nozzle and spray guns I15; and it is to be understood said main switch 21 controls, by appropriate circuits, all of the motors 9, I89, and electrically actuated blowers 2!! and 269, as well as energizing the various electro-magnetically operated valves H3 and I85. It is also to be noted the actuator lever 46 is provided with a hole 212 for registration with a corresponding aperture 213 in the connect-or wall 66 of the magazine and feed mechanism 5, see Figs. 1 and 7; so that when desired the pawling element 5! may be raised out of engagement with the tooth cam 53, by inserting a pin-not shown-into said hole 212 and aperture 213 when in registration, for a purpose later explained.

Referring also to the magazine and feed mechanism 5, the grooved spanning-wall 66 supporting the wear bars 68 and slide bars 14, said wall preferably seats at the sides in edge grooves 214, Figs. 6 and 11, in the spaced uprights 65, and it is provided at the lower portion with flanges 215 having extensions 216 slidable in grooves 211 in said spaced uprights 65, In addition, the flanges 215 have elongated slots 218 through which spaced clamp screws 219 engage correspondingly threaded holes in the uprights 65 whereby provision is made for adjustment of the plane of the wall 66, as well as the disk receiving and holder bar 82, into close proximity and true parallelism with the conveyor chain 23. This provision for adjustment of the holder bar 82 relative to the path of travel of the conveyor chain 23 is of prime importance, inasmuch as it enables prevention of flight caroming of the disks 40 from the inclined recess 84 in said bar under influence of the pressure air blast from the nozzle 85. Furthermore, in order to also prevent pocketing of air intermediate the disk 40 as it impacts the carrier 33 for engagement by the inclined lugs 35, said carrier is preferably provided with air escape holes 280. Fig. 11 therethrough, whereby any glancing action of the disk flight, in respect to the carrier 33 is effectively avoided. In other words, by the provisions just described, irregular impacts of the disks 40 against the carrier 33 is prevented, and failure of the disk 40 being automatically engaged by the lugs 35 rendered impossible.

The structural features of the invention, as well as the coordinative relationship of the several mechanisms having been explained, operation of the machine is briefly as follows. The operator first manually raises the outer end of the actuator lever 46, until the holes 212, 213 register, and then inserts a pin in said holes to hold the pawling element roller 52 out of engagement in respect to the tooth cam 53, whereupon the switch 213 is closed with resultant setting in motion of the motors 9 and, through the drive mechanism hereinbefore described, starts the endless conveyor 4. Concurrently the motors I80, as well as the centrifugal blowers 2II and 259 commence operating with the heaters 2I5 switched on; when the pressure air controlling switch 2' is also closed, and the necessary adjustments made so that the successive mask and resistance material depositing units I! will make the required application of such material with consistent individual predetermined ohms resistance. The trip device I86 is now applied to the conveyor chain 23 at a point in advance of the first mask and deposit unit I5I, so that the spray guns I15 will have been operating a short time before presentation of disks 40 therebefore for resistance deposit application, when the actuator lever 46 is released-by withdrawal of the hereinabove referred to pin from the holes 212, Zi3so that the roller 52 of the pawling element 5I coacts with the tooth cam 53, whereby the disk feeding ejector plate TI becomes intermittently activated to successively remove a rheostat disk 4|] from the inclined chute 56 into the province of the air nozzle 85. It will now be readily understood that the intermittent blasts of pressure air emitted by the nozzle 85 alternate in timed relation with the disposal of the consecutively released disks 43, in front of the collapsed end IIZ of said nozzle, so that the disk 40 is projected onto the registering carrier 33 for engagement by the inclined lugs 35, during the period of retraction of the ejector plate I1, and its positioning ready to release the next disk 40 from the chute 56. Immediately following the operation just described and, incident to continuous progression of the conveyor chain 23 the carrier 33, with the applied disk 41!, passes below the presser roller I38 which forces said disk into gripped relation by the inclined lugs 35 to prevent its oscillation to the right or left-hand, as hereinbefore explained. Continued progression of the conveyor 4 moves the consecutively applied disks 43 successively into the active zones of the several mask and deposit units I5I, for application thereto of the resistance material by the respective spray guns. II5. At this juncture and, as a typical example of the fluent resistance deposit applications which may be positively effected by the consecutive units I5I, reading from right to left of Fig. 1 and Figs. 37-46 (sheet 1) for producing disks 40 embodying a one-hundred percent effective rotation, for instance in a clockwise direction. In this connection the first endless mask I33 is provided with an aligned succession of spaced curvilinearly-related differential o and on apertures a, b, Fig. 37, for application thereto of silver deposits 0, d, Fig-42, of two to four ohms resistance approximately or 10% of the effective rotation; the second mask I33 having a succession of spaced sectoral apertures 6, Fig. 38, for applying a carbon deposit 1, Fig. 43, in circumferential continuity with the deposit d aforesaid, said deposit I being of five thousand ohms resistance and advancing to ap proximately 33 of the effective rotation; the third mask I63 has a sectoral aperture 9, Fig. 39, for making a carbon deposit h of ten thousand ohms resistance, Fig. 44, and advancing to 55% of the effective rotation; the fourth mask I63 having a follower sectoral aperture 2', Fig. 40, for making'a carbon deposit 7' of forty-five thousand ohms resistance, Fig. 45, with an advance up to 93% effective rotation; and the fifth mask I63 being provided with final sectoral apertures k, Fig. 41, completing the circumferential carbon deposit 1 of fifty thousand ohms resistance, Fig. 46, with a effective rotation; or completingthe annular carbon deposit up to the initial silver deposit. 0. Concurrent with the deposit applications 0, d, f, 7 and Z, it is to be noted the conveyor chain 23 is traveling through the active sphere of the drying system I with the carriers confronting the conduit openings I10, cowl outlets 22I, and dome elongate opening 222, whereby the moisture content of the respective resistance spray deposits is gradually evaporated with resultant progressive drying-out of said deposits. Also, incidental tothe operations just described, the trip device I8B will have been advanced into the field of the permanent magnet 229 and released from, as well as freed of engagement with, the conveyor chain 23 and carrier 33 as hereinbefore set forth. After leaving the drying system I the conveyor 4 advances the treated disks 4!) to the releasing mechanism 8 whereupon the kicker 241 removes the successively presented disks 4!] from engagement with the carrier gripping lugs 35, for individual guidance by the inclined chute 236, with the treated face uppermost, for consecutive placement on the endless conveyor 235, and transfer thereby to a suitable bake oven.

From the foregoing the invention will be clearly understood and its advantages fully appreciated, while it is also self-evident that when the air pressure is properly gauged, the spray guns Il'5 adjusted as required, and the consistency of the deposit solvent in the respective receptacles ill properly proportioned to the predetermined ohms resistance, that the machine may be run indefinitely, and that the discharged disks 40 will be automatically turned-out for final baking with positive assurance of equal and corresponding resistance capacity for each said disk.

While the foregoing description of the construction and operation of the resistance material desposit effecting machine, and the application of' same to use, will be readily understood; also that a simple and efficient means is provided for carrying out the stated objects of the invention. Still further, although one practical embodiment ofthe invention has been particularly explained with elements and means preferably adapted to perform the functions set forth, for a specific purpose, it is obvious that various changes in form and other applications of the inventive features may be resorted to, without departing from the spirit or sacrificing any of the advantages of this invention. 

